Box containers and the like



May 13, 1969 R. BRAKEWELL 3,443,466 BOX CONTAINERS AND THE LIKE I Filed Nov. 8,1966 Sheet Of5 PRIOR ART PRIOR ART y. 13, 1969 R. BRAKEWELL 3,443,466

BOX CONTAINERS AND THE LIKE Filed Ndv. a, 1966 Sheet 3 of 3 -FIG.5I-

May 13, 1969 R. BRAKEWELL BOX CONTAINERS AND THE LIKE Sheet Filed Nov. 8, 1966 United States Patent 3,443,466 BOX CONTAINERS AND THE LIKE Raymond Brakewell, 19 Ross Terrace, Broom, Ferry Hill, England Filed Nov. 8, 1966, Ser. No. 592,806 Claims priority, application Great Britain, Nov. 16, 1965,

Int. Cl. Gd 3/00 US. Cl. 84291 9 Claims ABSTRACT OF THE DISCLOSURE A method and apparatus for making a box container for a musical instrument or the like, wherein a liner strip having a longitudinal groove therein is secured to the inner faces of the top and bottom members of the box, the shape of the liner strip approximating the desired plan outline of the finished product. The side rib of the box is then secured in the longitudinal groove of the strip, the side rib being maintained in position by the grooved liner strips without the use of any jigs or the like to maintain the shape of the box during the setting of the joints.

This invention concerns improvements in and relating to box containers and especially to shaped containers and sound boxes for stringed musical instruments.

According to the prior art, a method of making a box container or the like having a curvilinear plan outline comprises forming the box top and bottom members to substantially the desired shape, forming a curvilinear groove corresponding to the desired plan outline in a face of the top and bottom memers, and securing a box side or rib in the grooves with the grooves locating an edge portion of the side or rib in relation to the top and bottom members. However, this method is suitable only for inexpensive instruments having relatively thick top and bottom members.

The method of this invention obviates the use, hereto fore regarded as essential in the production of musical instrument sound boxes, of a jig for each instrument for bending previously machined ribs to the required shape and maintaining the shape during attachment of liner and blocks, dressing them off and subsequent secural to the bottom member and a top member by glueing together the edge portions of the rib and the adjacent liner strips and blocks; the production of containers such as violin cases is also facilitated.

In one method of carrying out the invention a broad liner is secured on the face of the box bottom member, a groove forming operation may be employed to form a longitudinal groove therein in the shape of the desired plan outline of the final product.

In making a string instrument such as a guitar a box top member is made similarly, also being provided with one or more soundholes, adhesive is applied to the grooves in the liners and a rib is placed with its edge portions in the grooves, by which it is located in the required position. A neck is also fitted to the box, the neck preferably having grooves for receiving the ends of the rib one on each side, and extensions for attachment to the faces of the top and bottom members.

Spanish type guitars may be provided with a hardwood edge surrounding the top member, this preferably being formed from the liner. In this embodiment two wood patterns are used, one of which is finally the actual size and shape of the guitar whilst the second is smaller by the desired width of hardwood edge. The liner used in this embodiment extends both inwardly and outwardly of the actual size of the guitar and is provided with the necessary groove for receiving the ribs and a rebate for receiving 3,443,466 Patented May 13, 1969 the second or top member of the sound box. After assembly the excess liner is trimmed off, leaving the hard wood edge visible between the top member and the rib.

A further decorative purfiing may be added by machining the top member slightly smaller so that the purfiing may be accommodated between the hardwood edge and the edge of the top member or guitar front.

In making cello type guitars, double basses etc. the top and bottom members may be pressed into shape in a mould which preferably contains a suitable recess for accommodating the liners which are then glued to the top and bottom members during the pressing operation. After pressing, the top and bottom liners are grooved to receive the ribs. If the liners are glued to their respective members prior to the pressing operation difiiculties would arise as the members are pressed into shape.

In the manufacture of cheap guitars where an imitation purfling is painted on, the liner is unnecessary as the grooves in the top and bottom members provide sufiicient glueing surface for the rib. This is within the prior art.

In making a box container the side is located and secured in the groove in the bottom member and a hinged lid may be provided, in the case of a container for string instrument such as a violin case the groove and the located sides may extend round a tail-piece for enclosing the neck of the instrument.

The invention includes a box container or stringed instrument the sides or ribs of which extend below the surface of the bottom member; in the case of stringed instruments a finishing operation usually removes an external layer of the bottom and top members of the sound box so that the edge portions of the ribs may, at the outside, be flush with the finished surfaces of the top and bottom members.

In preparing the top and bottom members a routing machine is preferably employed in conjunction with a jig pattern which has a surface recessed in correspondence to the groove and usually also to the outline of the members and to the soundhole (s). Thus one simple jig pattern is required for each shape required instead of, as heretofore, a costly assembly jig for each instrument in simultaneous production.

In a still further embodiment of the invention, a wooden liner of substantially U-section is made of a length equal to the periphery of the instrument to be constructed, and having a rib groove preformed therein. This liner is then repeatedly and deeply slotted from one side so as to render it flexible.

Next a jig is made, having a curved groove slightly larger than the section of the liner, the groove being the approximate shape of the final instrument or box. The liner is laid rib-groove downwards in the jig groove and its exposed face is glued, the base (or top) of the instrument being placed on it and left till the glue sets. It is then removed from the jig. The process is repeated with the top (or base) of the instrument. A rib is now bent to shape and one edge inserted into the rib groove of one of the top (or bottom) liners, and secured by glue. Finally the remaining bottom (or top) member is secured to the rib.

This removes the need for cutting a liner from a solid piece of wood, and so saves a considerable quantity of material. As an alternative, the liner may be made of a strip of pre-formed plastics material, in which case the slots may not be necessary.

The invention will now be described further, by way of example, with reference to the accompanying draw ings, in which:

FIG. 1 shows a multi-channeled jig pattern for use in prior art methods of producing sound boxes;

FIG. 2 shows a liner afiixed to a top member of a guitar in accordance with the invention;

FIG. 3 is an enlarged fragmentary section through a liner and a top member;

FIG. 4 is an exploded view showing the neck end of an instrument and a prior art rib mounted on the bottom member;

FIG. 5 is a section through an alternative form of liner and top member;

FIG. 6 shows a section through a mould for shaping a top member;

FIGS. 7 and 8 are respectively top and end views of a flexible slotted liner;

FIG. 9 is an alternative form of liner in end view;

FIGS. 10 and 11 show a section and top view of a further form of liner; and

FIG. 12 shows a curved perspective view of a liner.

FIG. 1 shows a jig pattern 1 for use in conjunction with a router type copying machine to produce the top and bottom members of e.g. a musical instrument sound box in accordance with prior art methods. The jig pattern 1 has a pair of channels 2 ,3 formed in it, and may also have a hole such as indicated at 4 corresponding to a sound hole of the instrument. This jig is placed on the router, and on the work place of the machine is placed a piece of wood from which a top or bottom member is to be made. The cutter of the machine engages the wood as the copying point is placed in the outermost groove 2 of the jig 1 and taken round its periphery. This cuts out from the wood a piece of material of the approximate shape of the box to be formed.

The copying point of the router is then placed in the inner groove 3 and again the cutter is brought into contact with the wood, this time to cut a groove in the top or bottom member to receive one edge of a box side or rib 8 (FIG. 4). Excess material of the top and bottom memhers is trimmed off after the side or rib 8 has been secured in position. The side or rib 8 is preferably secured by means of a quick setting adhesive. The top member may be provided with one or more sound holes by engagement of the router machine point with e.g. the hole 4.

Where the top and bottom members are too thin to receive a groove of sufiicient depth to adequately support the rib 8, a liner strip may be adhered to the top and bottom members prior to forming the grooves and so positioned as to substantially follow the line of the intended grooves. In this arrangement the groove forming operation is simultaneously employed to trim the edge of the liner adjacent to and running along the inner edge of the groove and also, if necessary, to trim the inner edge of the liner remote from the groove. Such a liner designated 6, is shown in FIGS. 2 and 3 where it is shown attached to a top member 5. A groove 7 is shown circumscribing the liner 6. FIG. 3 shows a fragmentary section through this arrangement.

FIG. 4 shows one end of a musical instrument with a rib 8, mounted on a bottom member 9 with the aid of a liner 10, the rib 8 being bent to shape, inserted in the groove, and glued in position. The rib 8 extends all the way round the periphery of the musical instrument with the exception of a gap 11 provided to accommodate a neck 12 having a slot 13 on each side to engage the ends of the rib defining the gap 11. The neck is slid into place on the ends of the rib and a top member, also with groove and liner, is placed on the top edge of the rib. The bottom member 9, with its rib 8 previously glued in position, the neck 12 and the top member such as the top member 5 of FIGS. 2 and 3, are then glued together with the end 14 of neck 12 glued directly to the bottom member 9. The neck may be provided with an extension 15 which rests on the top member of the instrument.

FIG. 5 shows a liner 16 according to this invention which is so formed as to provide a hardwood edge between the top member 19 and the rib 18. In this arrangement the liner 1 6 contains the rib groove and also has a rebate 17 cut from the side of the liner remote from the groove. The rebate 17 need not be provided, in which case the upper surface of the liner 16 is secured to the inner face of the top or bottom member of the box. The top or front member 19 is smaller than the overall dimensions of the sound box by the desired width of hard- Wood edge, and is placed in the rebate in the liner 16 and glued in position. Finally the rib 18 is bent into shape and placed in the groove of the liner 16 as described above. The top member may either fill the rebate completely, or it may leave a space 20 for the insertion of a decorative purfling. When the instrument is fully assembled and all the adhesive has solidified, the portion 21 of the liner may be removed by routing or planning so as to leave a flat side all the way round the instrument.

FIG. 6 shows a section through a mould 22 for shaping a top member 24. The mould 22 has a channel 23 formed in it to receive a liner with its rib receiving groove downwards. The top member 24, which may be plywood or any other material which can be shaped by heat or steam, is

I placed on the mould and pressed into position. It is, of

course, preferable to shape the top member 24 by pressing it over the curved mould before securing the liner to it, as otherwise the liner may be subject to stresses and become detached from its member..

In good quality instruments where the top and bottom members are too thin to receive a groove, the groove may be provided wholly within the liner, even where no hardwood strip or decorative purfling of the type described in relation to FIG. 5 is required. Such a liner is shown in FIGS. 7 and 8, and consists of a strip of wood in which a groove 26 is cut. A number of deep transverse slots 27 are also cut in the strip, and the latter may be backed by a piece of adhesive tape 28 to ensure that the wood does not break apart, whilst permitting the liner to flex about the tape. A pattern of a form similar to that of the jig shown in FIG. 1, except that it contains only one channel with a cross-section corresponding to the cross-section of the strip of wood 25 before it is grooved and slotted, is preferably used to position and shape the liner. The liner may be placed in the channel with its groove 26 facing upwardly, in which case a rib is located and glued in the groove 26 and the liner and rib subsequently glued to a top or bottom member. Preferably, however, the liner is inserted in the channel with its groove 26 facing downwards. The upper face of the liner is then glued, and a top or bottom member lowered on to it and pressed into contact. Preferably the edge of the liner with the adhesive strip 28 is positioned outwards of the body of the instrument, and again preferably the strip 28 and the wood which it covers is machined off when the instrument has been assembled. Any holes left visible from the bottom of the slots 27 are covered by a strip of beading or other decorative material.

FIG. 9 shows an end view of a liner or similar construction to that shown in FIGS. 7 and 8, but having a quadrant section. In this, the inner face of the liner is curved to give a decorative effect to the liner when seen through the sound hole in the instrument.

FIGS. 10 and 11 show a section and top view respec tively of another form of liner which is a modification of the liner shown in FIG. 5. This liner has transverse slots 30, 31 on opposing sides, a groove 32 on top to receive a rib a slipped rebate 33 to receive a bottom (or top) member, and channels 34 and 35 into which stringing or purfling 36 is laid. After the instrument made with this liner is glued up, the surplus material 37 is trimmed off the liner and purfling to lie flush with the rib and bottom (or top) member.

Finally FIG. 12 is a perspective view of a bent liner, having slots on both inner and outer faces 40 and 41, and a rib groove 42. The outer wood to the base of the groove 42 is machined off after assembly of the instrument.

Although the liners described above have been referred to as wood, it should be understood that this material is not absolutely essential, although its acoustic properties are such that it is often preferred. However, a strip of extruded plastics material may be employed in place of wood should this be thought to be desirable. Since the plastics material can be chosen to be flexible in itself, the transverse slots may not be necessary.

I claim:

1. A method of making a box container or the like having a curvilinear plan outline and including top and bottom members and a side rib, comprising the steps of:

forming at least one of said members to substantially a desired shape; securing a liner strip to a face of at least one member, the shape of said strip approximating the desired plan outline; forming a curvilinear groove corresponding to the desired plan outline in a face of said liner strip; and securing said side rib in said groove, thereby locating an edge portion of said side rib in relation to said member.

2. A method according to claim 1, wherein said liner strip is formed from a flexible strip of material, transversely slotted to improve its flexibility, further comprising the step of shaping said liner to the desired plan outline by inserting it in a channel of a jig pattern, said member then being selectively secured to said liner strip while the latter is located in said channel.

3. A method according to claim 1, wherein said liner strip is a flexible strip of material having a longitudinal rib-receiving groove and a plurality of transverse slots on each side of said groove, and wherein said liner is secured to said member such that said longitudinal groove corresponds substantially with the desired curvilinear plan outline, further comprising the step of removing the liner portion disposed outside said side rib such that the liner portion below the base of said groove is visible in the finished article.

4. A method according to claim 3, further including the step of inserting a decorative purfling into said ribreceiving groove prior to the securing of said side rib.

5. A method according to claim 1, comprising the steps of:

securing a second liner strip to a face of the other of said top and bottom members, the shape of said second liner strip approximating the desired plan outline;

forming a curvilinear groove corresponding to the desired plan outline in a face of said second liner strip; and securing an edge portion of said side rib in said groove of said second liner strip.

6. A musical instrument including a sound box having a curvilinear plan outline, said sound box comprising:

box top and bottom members conforming to said plan outline;

a longitudinally grooved and transversely slotted liner secured to an inner face of at least one of said top and bottom members;

and a side rib having an edge region secured in the longitudinal groove of said liner, the portion of said liner disposed outside said side rib being removed to make visible the liner portion below the base of said groove.

7. A musical instrument according to claim 6, further comprising a second longitudinally grooved and transversely slotted liner secured to the inner face of the other of said members, said side rib having a second opposing edge region secured in said longitudinal groove of said second liner, the portion of said second liner disposed outside said side rib being removed to make visible the liner portion below the base of said longitudinal groove in said second liner.

8. A musical instrument according to claim 6, wherein said liner has a rib-receiving groove formed in one side thereof and a rebate cut from the side thereof remote from said groove, said liner accommodating an edge region of at least one of said top and bottom members within said rebate such that said liner present a decorative edge between said side rib and said member after any excess material has subsequently been machined off.

9. A musical instrument according to claim 8, wherein said liner is grooved to receive a decorative purfling.

References Cited UNITED STATES PATENTS 687,097 11/ 1901 Wolfram 84267 FOREIGN PATENTS 379,119 8/ 1907 France.

RICHARD B. WILKINSON, Primary Examiner.

J. F. GONZALES, Assistant Examiner.

' U.S. Cl. X.R. 29--462 

